Display Via Layer Thickness and Electrode Gap Alignment
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Solution Overview
Problem
Existing display devices face challenges in controlling the thickness of the via layer and the alignment of electrodes, which affect display quality.
Innovation Solution
A display device design with a via layer thickness of 2-5 μm and a separation distance of 3.0-3.5 μm between electrodes, using a resin composition comprising an acrylic resin, multifunctional acrylic monomer, photoinitiator, and solvent, allowing precise control of electrode alignment through an electric field.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the via layer thickness is increased to improve electrode alignment and display quality, then the manufacturing complexity and material consumption increase
Solution Approach 1:
The patent applies parameter changes by optimizing the via layer thickness to a specific range (2-5 μm) and controlling the separation distance between electrodes (3.0-3.5 μm). These parameter adjustments resolve the contradiction by achieving precise thickness control that ensures proper electrode alignment and display quality while avoiding excessive material consumption and manufacturing complexity associated with thicker layers.
2Manufacturing precision
If the separation distance between electrodes is increased to improve alignment, then the display area and device size increase
Solution Approach 1:
The patent resolves this contradiction by optimizing the separation distance parameter to a specific range (3.0-3.5 μm). This parameter adjustment achieves sufficient electrode alignment for high-quality display while minimizing the impact on overall display area, thus balancing alignment precision with area efficiency.
3Manufacturing precision
If the via layer thickness is precisely controlled to ensure electrode alignment, then the manufacturing process complexity increases
Solution Approach 1:
The patent addresses this contradiction by establishing specific parameter ranges for via layer thickness (2-5 μm) and separation distance (3.0-3.5 μm). These parameter specifications provide clear manufacturing targets that enable precise thickness control and uniformity while maintaining reasonable manufacturing processability, avoiding overly complex processes.
4Manufacturing precision
If the resin composition is optimized to control via layer thickness, then the material formulation complexity increases
Solution Approach 1:
The patent applies composite materials by formulating a resin composition containing acrylic resin, multifunctional acrylic monomer, photoinitiator, and solvent in specific proportions. This composite material approach resolves the contradiction by achieving precise via layer thickness control through optimized material composition while managing formulation complexity through a well-defined multi-component system.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enhances display quality by ensuring appropriate thickness and alignment of electrodes, improving the structural integrity and performance of the display device.
Implementation Method 1
a photoinitiator, and a solvent. An amount of the resin material may be in a range from about 3 wt % to about 10 wt % with respect to an entirety of the resin composition
Data Source
AI summary
According to an embodiment of the disclosure, a display device, a resin composition, a method of manufacturing the display device, and an electronic device comprising the display device are provided. The display device includes a base layer, a conductive layer on the base layer, a via layer covering the conductive layer, an electrode layer disposed on the via layer and including a first electrode and a second electrode spaced apart from each other by a separation distance, and a light-emitting element between the first electrode and the second electrode. The conductive layer may be overlapped with the electrode layer in an overlapping area in a plane view. The via layer may have a medium thickness, which is equal to or more than 2 μm, in the overlapping area. The separation distance may be equal to or more than 3.0 μm.